Valve apparatus



Oct. 30, 1945. E. A. ROCKWELL 2,388,220

VALVE APPARATUS Original Filed April 11, 1941 4 SheetsSheet l lllll lll ll l INVENTOR BY Q QM ATTORNEY 0a. 30, 1945. E, A, ROC WELL 2,388,220

VALVE APPARATUS Original Filed April 11, 1941 4 Sheets-Sheet 2 INVENTO ew Q QM ATTORNEY Oct. 30, 1945. A RQCKWELL 2,388,220

VALVE APPARATUS Original Filed April 11, 1941 4 Sheeis-Sheet 5 IMM'IIII Q u ATTORNEY Oct. 30, 1945. ROCKWELL 2,388,220

VALVE APPARATUS Original Filed April 11, i941 4 Sheets-Sheet 4 INVENTOR WQIWM Patented Oct. 30, 1945 UNITED STATES,

PATENT OFFICE Original application April 11, 1941, Serial No.

388,003. Divided and this application February 17, 1943, Serial No. 476,245

8 Claims.

My invention relates particularly to valve ap- Daratus designed for controlling the movement of any device for work-performing action, but which is especially applicable to the operation of brakes on automotive vehicles. 6

The present application is an improvement over my application upon Power system, Ser. No. 239,436, filed November 8, 1938, and is a division of my application upon Power intensifier valve, Ser. No. 388,003, filed April 11, 1941.

The object of my invention is to provide a valve mechanism capable of applying the desired amount of power for the operation of workperforming devices, such fo example as automotive brakes, etc., in which efiective modulation of the power and manual pressure applied, or either of them, can be obtained at all times. Another object is to arranged the manual actuating device so as to perform some of the work in applying power, thereby obtaining a short travel of the manual means in the operation of the power unit and thus obtaining a greater sensitivity of control than where these elements are disassociated, as in my previous application above referred to. This arrangement permits the operation to be effected with substantially the same pedal range at all times. One of the objects, furthermore, is to mount the liquidtransfer valve on the valve operating means controlling the fluid pressure inlet instead of on the power-applying means, as in said application. Also, by having the power-applying means operate so as to exert a pull instead of a pushing action, the transfer valve can be located adjacent to the intensifying cylinder, which results in avoiding long tubing and air bleeders, and a common air vent can be used for all the parts. Also, the apparatus, which is balanced throughout, operates with the aid of inlet and outlet valves which may be operated to control the application of a vacuum and the atmospheric air on opposing sides of the movable wall in such a way that the atmospheric air, being admitted, has a counter-balancing action, due to the diaphragm connections, against the valves so as to prevent the unseating of the air inlet valve by the incoming pressure of the atmospheric air. How.- ever, a superatmospheric air pressure can be substituted for the atmospheric air and atmospheric air pressure for the vacuum, if desired. Due to the short travel, furthermore, a diaphragm with:

a small return spring can be used effectively, as the movable wall and substantially the whole area of said diaphragm acts as a regulator of the valves which are mounted thereon. Further obiects of my invention will appear from the detailed description of the same hereinafter.

While my invention is capable of embodiment in many different forms, for the purpose of illustration I have shown only one form thereof in the accompanying drawings in which- Fig. 1 is a perspective view showing the parts of an automobile chassis to which myinvention is applied;

Fig. 2 is an elevation partly in section of a master cylinder used in accordance therewith;

Fig. 3 is a plan view of a power unit made in accordance with my invention, with the air filter removed; Y

Fig. 4 is an end elevation of the same;

Fig. 5 is a longitudinal section thereof taken on line 5-5 of Fig. 3;

Fig. 6 is a vertical section taken on line 6-6 of Fig. 5 showing the relative location of the valve-operating lever and diaphragm valves operated thereby;

Fig. '7 is a detailed section showing the mounting of said valve-operating lever taken on line l-'| of Fig. 6; and

m Fig. 8 is a vertical section of a modified air inlet device.

Referring to the drawings, I have shown a pedal I mounted on a fixed pivot 3 at any desired point on an automobile chassis (not shown) which has an operating link 4 attached to said pedal, which in turn is connected to an operatin lever 5 of a master cylinder 6. The master cylinder 6 may be constructed in accordance with any desired type of master cylinder but may, for example, be constructed in accordance with the master cylinder shown in the Loughead Patent No. 1,707,063, granted March 26, 1939. The operating lever 5 may be mounted on a. shaft 1 which extends into said master cylinder, and on said shaft 1 within said master cylinder 6 there is an operating arm 8 which bears upon a piston 9 that extends into a cylinder III which is in communication with the liquid in the master cylinder 6 by means of a port II, which port II is uncovered in the retracted position of the piston 9. The said master cylinder 6 thus acts as a storage chamber for the hydraulic liquid and is provided with a cover I 2 having a vent l3, said cover having the usual removable filler cap M. The cylinder Ill has the usual spring I5 for retracting the piston 9 and a flexible discharge conduit I 6 which leads to a screwthreaded fitting lfia on a power unit ll, said powerunit I I having a flexible discharge pipe l8 which leads by any desired branch pipe to erate the usual brake shoes 28 and 2| providedin connection with all of said wheels for cooperating with brake-drums (not shown) thereon. The said pipe I8 is connected by a screw-threaded fitting 24 to a plunger housing 25 of the power unit, said housing having projections 28 and 27 carrying studs 28 and 29 as well as nuts 38 and 3| to hold in place tightly clamping members 32 and 38 which are arranged to be clamped around a steering column 39 of the automobile chassis. Also secured to said plunger housing 25 there is a rear shell 35 secured in place by screws 38. The said rear shell 95, by means of screws 91, clamps in place a main diaphragm 38 against a forward shell 89 which has a screw-threaded sleeve 48 secured thereto and which communicates by a fitting with a flexible pipe 82 which leads to a manifold 83 of the internal combustion engine mounted on said chassis for driving the automobile. The sleeve 98 contains a check valve 99a provided with peripheral notches 98b and having a cylindrical valve seat 83c cooperating therewith.

The liquid forced manually out of the master cylinder 8 and received by the power unit H from the pipe I8, enters through a coupling member 48 in said plunger housing 25 into a valve chamber 95. This chamber 95 has a peripheral recess 85a into which there is sprung a liquid distributor plate 45b having near the edge thereof a marginally arranged series of notches 950 to distribute the force of the incoming liquid, thus avoiding undesirable impact on the inlet valve. The initial operation of the brakes by the manual force applied, causes the liquid to flow into a chamber 96 in a plunger sleeve 97 having ports 98 leading to a cylindrical chamber 99. The plunger sleeve 91 has a U-shaped rubber seal 58 and carries within the same a valve stem or plunger 5i having a head 52 thereon, beneath which there is a rubber gasket 53 arranged to act as a compensating inlet valve, the seat for which is a shoulder 59 on the plunger sleeve 91, so that when thus seated the hydraulic liquid, which in the initial operation of the apparatus is conveyed from the cylinder 99 by a port 55 to a pressure cylinder 58 and thence to the brakes through the pipe I8, is cut ofi by said valve 53, 54 so as thereafter to apply the power from the power unit. It will be noted that the valve stem 5I or plunger serves as a supporting guide for the plunger sleeve 91 which is reciprocable to some extent on said valve stem. The movement of the plunger sleeve 91 to the right, in Fig. 5, is limited by a stop 51 formed on the interior of the coupling 99 and the movement of said plunger sleeve 41 to the left of said figure is limited by a plunger sleeve 58 which is screw-threaded on the said stem 5|.

The plunger sleeve 58 has thereon a plunger 59 and an annular rubber seal 98. The said plunger 59 operates in a cylindrical chamber 8| which carries a coil spring 82 normally forcing the plunger 59 to the right'so as to unseat the valve 53, 58, which when open compensates theliquid on the two sides of the valve. The other end of said spring 82 rests against a sleeve 83 located tightly in the end of the chamber GI, said sleeve having a cap ring 84 and a leather gasket 65 around a rod-shaped plunger 66 carried within a bushing 61 within the sleeve 83. The said rod-like plunger 68 bears at its rear end against the plunger 59 and at its forward end bears assaaao against the end of a valve-operating lever 98, which in turn operates a spring 69 located around a guide rod 78 having a screw-threaded reduced end II passing through plates 12 and 19 clamped around an opening I8 in the diaphragm 98, where it is held in place by a nut 15. The plates 12 and I3 are secured together by screws 19a at the periphery thereof and screws 13b located on opposite sides of a laterally offset portion 130 of the plate 12. The said lever 88 is supported by a pivot 18, which can be placed at any desired point along said lever to obtain the desired lever ratio, on a rod Tl having a screwthreaded end 18 passing through the plate I8 to which it is tightly held by a nut 19. The other end of the lever 88 has a pivot 88, by means of which it is pivotally connected to a valve-operating sleeve 8| screw-threaded on a valve stem 82 having a vacuum or outlet valve head 83 connected thereto and which carries within the same a rubber washer 99. The said rubber washer seats upon an annular valve seat 85 which is clamped to a subsidiary diaphragm 86 supported by screws 81 and a clamping ring 88 from the plate 12. This clamping to the diaphragm 88 is accomplished by means of a clamping plate 89 held in place by a valve sleeve 98 screw-threaded to the annular valve seat 85. A coil spring 9| bears at one end against the clamping plate 89 and at the other end against the plate 13 so as to normally force the valve sleeve 98 to the left of Fig. 5 and thus seat a rubber washer 92 of an air valve or inlet valve 98 against an annular valve seat 99 carried in the plate I3. It will be noted that the valve sleeve 98 has air ports 95 leading from within the sleeve to the interior of the shell 95. The air which is admitted to the interior of the shell 35 through thevalve 98 is received from openings 98 communicating with a chamber 91 between the plates I2 and I3, said opening 96 being provided in a screw-threaded plug 98, having a leather'gasket 98a, passing through the plates 12 and 13. A hollow plunger 99 is screw-threaded to the plug 98 which has a central passageway I88 communicating with a longitudinal passageway I8I in the plug 98. This hollow plunger 99 clamps the plate 13 against a shoulder I82 on the said plug 98. Ports I89 in the said plunger 99 communicate with a cham ber I89 in the said plunger housing 25 which has an air vent I85 leading to the outer air through a tube I85a. leading to an air filter casing I851), filled with horse-hair, having a headed sleeve I85c, with openings I85d, screw-threaded to the tube W511 and provided with a shoulder I85e against which a plate I85f rests, which has air vent openings I859. The chamber 8| is also con nected to said vent I85 by a passageway I88 located between the chambers BI and I89. The said chamber I89 has a screw plug I81 which merely fills an opening I88 used for convenience in drilling the passageway I88. Furthermore, the said chamber I89 has a bushing I89 and outside the same a sleeve II8, which is tightly carried within the chamber I84. The end of the sleeve H8 is screw-threaded to a cap III which acts as a stop in the movement of the plate 13 and also serves to hold in position a leather seal II2 against the outside of the hollow plunger 99. Within the hollow plunger 99 there is a rod I I3, operating in an air transfer passage 3a, the rear end of which rod is screw-threaded into a plug IId acting as a closure for the cylindrical chamber 58. On the forward end of said rod I I3 there is a head I I5 holding in place a washer threaded to a plunger stem I20 passing through a guiding sleeve I2I held in place in the chamber 56 by a screw I22. The said plunger I20 carries rubber seals I23 and I24 between which there is carried a coil spring I25 on the plunger stem I20, which in turn has a plunger head I26 adiacent to the rubber seal I24, which exerts a pull induced by the diaphragm 38 to place the liquid in the chamber 56 under increased pressure due to the relative sizes of the diaphragm 38 and the plunger I26.

In assembling the power unit it will be understood that the diaphragm 38, plates 12 and 13 and the valve elements together with the operating lever 68 mounted thereon, can be made into one assembly and the plunger mechanism made into another assembly and that these two assemblies can then be assembled together while at the same time securing the shells 35 and 39 thereto.

In Fig. 8 I have shown a modified air inlet device in which there is provided means for adjusting the amount of air admitted at diflerent altitudes at which the automobile is operated and so as to control the outlet pressure of the apparatus. In this figure I' have shown connected to the air vent port I a screw-threaded tube I21 having a flared portion I28 provided with a flange I29 against which there is clamped a rubber diaphragm I30, having a central aper ture I3I, by means of screws I32 passing through the diaphragm into said flange I29 and Passing through a flange I33 on an air valve housing I34 provided with air ports I35. The upper portion of the housing I34 has a screw-threaded opening I36 through which there is arranged to pass.

an adjusting screw I31 provided with a knurled head I38. On the screw I31 there is a lock-nut I39 so as to hold in place above the housing I34, an air filter shell I40 filled with horse hair and which has a depending rim I so arranged as to leave an annular air inlet I42 between the same and the flanges I29 and I33. The adjusting screw I31 has a rounded lower end I43 which is received in a recess I44 in an air valve plate I45 having a downwardly directly rim I46, the air valve plate I45 being pressed upwardly by a compressed spring I41 which is supported at its lower end on a shoulder I48 within the tube I21. The rim I46 is arranged to be adjusted into or out of contact with the diaphragm I30 so as to provide an air passageway I49 between the valve plate I45 and said diaphragm I30. The diaphragm I30 is supported inits uppermost position by a supporting ring I50 which is dished upwardly so as to receive a coil spring I5I seated at its lower end ona shoulder I52 in the inside of the flared portion I28 of the tube I21. When operating the automobile at high altitudes the spring I5I will be in its position of full extension with the plate I45 adjusted out of contact with the diaphragm I30, whereas at lower altitudes or where the output pressure applied to the brakes is to be lessened, the plate I45 will be adjusted into contact with the diaphragm I30 so as to compress the spring I5I more or less, as desired, according to the position of the screw I31.

In the operation of the apparatus, when it is desired to apply the brakes the pedal I is moved to the left, in Fig. 1, whereupon some of the liquid from the master cylinder 6 passes from the pipe I6 through the valve chamber 45, ports 48, port 55, chamber 56 and pipe I8 to the wheel brake cylinders I9 so as to move the brake shoes 20 and 2| up into position, for applying the main braking effect. A further increase of this manual pressure from the pipe I6 will cause the piston 59 to move forwardly in the chamber 6|, 'thus closing the valve 53, 54 and simultaneously operating the lever 68 so as to move the valve 83 into closed position while moving forwardly, slightly, the plates 12 and 13 as well as the diaphragm 38 through the intermediary of the spring 69. Further increase of the manual pressure, resulting in further movement of the plunger rod 66 in this direction, results inopening the air inlet valve 93 due to the further movement of the lever 68 and the yielding of the diaphragm 86. The opening of the valve 93 admits the air to the desired extent from the vent I05, ports I03, chamber I00, passageway IOI, ports 96 and thence to within the rear diaphragm shell on the right of the diaphragm 38. This exerts a hydraulic pressure in the chamber 56 which by its reaction has a tendency to move the diaphragm 38 in the opposite direction to its direction of movement by the manual force applied. The effect of this incoming air from the valve 93 is balanced between said valve 93 and the diaphragm 86 so as to prevent the valve 93 from being suddenly opened by said incoming air. It will be noted, furthermore, that the air ma be admitted, in this way, to the chamber within the shell 35 in any desired increments and that between the accession of such increments to the right of the diaphragm 38 the two valves 83 and 93 will be in lapped or closed position due to the pneumatic pressure, above referred to, tending to move the diaphragm 86 downwardly in Fig. 'I

in any one position of power application in which the pedal I is held. In other words, as the diaphragm 58 moves to the left, in Fig. 5, the pivot 16 is carried thereby, and upon cessation of movement of the pedal I, while the valve 93 is still open, the diaphragm 38 will still continue to move to the left slightly as the left hand end of the plunger I06 is then a stationary pivot. At this time, also, a slight movement of the lever 68 affects the valves 83 and 93, to move them into lapped position. Consequently, the said valves can apply a modulated degree of pressure to the right side of the diaphragm 38, as desired, while transmitting through said valves and lever 68 to the manual means a reaction due to the differential pressures on opposite sides of the valve 84, 85 supported on the diaphragm 86. Similarly, the air may be withdrawn by increments in the same -manner from the right of the diaphragm 38 through the opening of the valve 83 to the desired extent for this purpose, by lessening the tent desired and as determined by the manual pressure from the pedal I, thus applying the power pressure through the pipe I8 to the brakes and exerting the reaction from the chambers 56 and 49 on the foot through the pedal I. This pressure exerted on the brakes may be of any desired maximum but may, for example, be about 1500 lbs. per square inch, whereas the manual pressure applied from the master cylinder may, for example, be frame to 600 lbs. per square inch, or any other ratio of these or other pressures can be obtained, as desired. In view of the fact that liquid from the master cylinder is directly connected to and takes part in the movement of the brake shoes 20 and 2I, the said diaphragm produces the desired power pressure on the brakes with a very short path of travel of the manual means and which obviously is a shorter path of travel than would be the case if the brake shoes 20 and 2I were moved only by the air pressure acting on the diaphragm 38. Because of this arrangement, in which the foot always performs a part of the work by supplying a part of the liquid used in applying the brakes, even when the power is being applied about 40% of the liquid in applying the brakes is provided by a ual pressure and the power pressure proportionally thereto. However, in this power unit, whatever force is supplied manually by the foot pedal I is entirely offset by an equal and opposite force from the power piston I28 so that, consequently, all the brake-applying force for operating the brakes, when the power is on, is derived entirely from the power plunger I20. This apparatus is thus a full power unit. For these reasons, also, the brake is practically as eiIective, irrespective of considerable variations in the vacuum from the manifold, due to the direct connection just referred to and the large size of the diaphragm 38. Furthermore, it will be noted that at all times a reaction passes from the liquid applied in the operation of the brakes back to the foot, through the pipe I8 either from the liquid in the chamber 49 through the valve 53, 54 when this valve is open at the beginning or towards the end of the application of manual pressure, or from the chamber 49 on the plunger sleeve 41 when said valve is closed, thereby making the degree of application of the brakes readily ascertainable without the pedal being moved towards its off position. Also, the actuation of the brakes is made more eflective by reason of 'the coordination of the travel of the pedal I to the movement of the brakes, as it will be evident that the movement of the brake liquid is coordinated to the travel of the liquid supplied from the master cylinder. In order to throw the brakes out of operation, the manual pressure on the pedal'is fully released, whereupon the spring 69 opens the valve 83 and allows the valve 93 to close and the springs I I1 and I25 withdraw the diaphragm 38 to the right, thus admitting vacuum thence through the ports 95 to the right of the diaphragm 38. This action is accompanied by the unseatins of the valve 53, 54, thus restoring the parts again to their original positions and compensating for any possible loss of liquid in the power unit, ready for the application of the brakes as desired.

In the modified form of air inlet apparatus as shown in Fig. 8, the adjusting screw I 31 is arranged to adjust the air inlet plate I 45 to any desired position according to the altitude at which the automobile is operating or according to the amount of the maximum output pressure desired to be applied to the brakes. In other words, when the automobile is operating at a high altitude, with consequent lessened atmospheric pressure, the plate I45 will be adjusted upwardly to a position away from contact with the diaphragm I30. When, however, the automobile is operating at a lower altitude, or when it is desired to decrease the maximum available pressure output supplied to the brakes, the plate I45 will be adjusted downwardly by the screw I31 until it contacts with the diaphragm I30 or until, by further adjustment, it compresses the spring I5I to the point desired. Of course, when the apparatus is being operated to apply pressure to the brakes, the incoming air will in any case pass through the air inlet I42, ports I35, passage I49 and thence into the tube I2'I, thus applying to the diaphragm I38 a degree of the vacuum existing at the right of the diaphragm 38, in Fig. 5. When the valve plate I45 has been adjusted into contact with the diaphragm I30, the incoming air pressure will move the diaphragm I38 downwardly by compressing the spring I5I.

It will be understood that instead of supplying a vacuum to the fitting 4| this may be a vent and that instead of the port I 05 being a vent this may be connected to a source of superatmospheric air pressure.

While I have described my invention above in detail I wish it to be understood that many changes may be made therein without departing from the spirit of the same.

I claim:

l. A valve structure comprising a movable wall, an enclosure containing the same, inlet and outlet valves provided with valve members having a. fluid pressure-responsive supporting means for said valves yieldingly mounted for independent fluid pressure-responsive movement relative to and on said wall, a source of fluid pressure for moving the wall controlled by the valves, said valves being relatively movable, and means mounted on said wall for opening and closing said valves.

2. A valve structure comprising a movable wall, an enclosure containing the same, inlet and outlet valves, having a valve supporting flexible diaphragm mounted for independent fluid pressureresponsive movement relative to and on said wall, a source of fluid pressure for moving the wall controlled by the valves, said valves being relatively movable, and means mounted on said wall for opening and closing said valves.

3. A valve structure comprising a movable wall in the form of a diaphragm having valve-supporting plates thereon, an enclosure containing the same, inlet and outlet valves provided with valve members having a. fluid pressure-responsive supporting means for said valves yieldingly mounted for independent fluid pressure-responsive movement relative to and on said wall, a source of fluid pressure for moving the wall controlled by the valves, said valves being relatively movable, and means mounted on said wall for opening and closing said valves.

4. A valve structure comprising a movable wall in the form of a, diaphragm having valve-supporting plates thereon, an enclosure containing the same, inlet and outlet valves, having a valvesupporting flexible diaphragm mounted for independent fluid pressure-responsive movement relative to and on said wall, a source of fluid pressure for moving the wall controlled by the valves, said valves being relatively movable, and means mounted on said wall for opening and closing said valves.

5. A valve structure comprising a movable wall in the form of a diaphragm having valve-supporting plates thereon, an enclosure containing the same, inlet and outlet valves mounted on said wall, a source of fluid pressure for moving the wall controlled by the valves, said valves being relatively movable, and means mounted on said wall for opening and closing said valves, said inlet and outlet valves comprising a tubular valve member containing an inlet valve member and an outlet valve member rigidly supported thereon cooperating with said plates and a valve-operating stem passing through the tubular valve memher and carrying a, valve element on said stem.

6. A valve structure comprising a movable wall in the form of a diaphragm having valve-supporting plates thereon, an enclosure containing passing through the tubular valve member and carrying a valve element on said stem.

7. A power unit, having a casing, a source of vacuum, a flexible diaphragm in said casing adapted to be operated by the vacuum, a clamping plate, having an atmospheric air inlet passageway, mounted on the diaphragm, a plunger yieldingly connected to said diaphragm, a valve apparatus having a fluid pressure-responsive mounting yieldable relative to said diaphragm and having a vacuum valve and an air valve. said air valve being adapted to control the passage of atmospheric air pressure through the passageway to one side of the diaphragm when the vacuum valve is closed, and means for controlling .the operation or the valve apparatus by said plunger.

8. A power unit, having a casing, a source of vacuum, a flexible diaphragm in said casing adapted to be operated by the vacuum, a clamping plate, having an atmospheric air inlet passageway, mounted on the diaphragm, a plunger yieldingly connected to said diaphragm, a valve apparatus on said diaphragm having a vacuum valve and an air valve, said air valve being adapted to control the passage of atmospheric air pressure through the passageway to one side of the diaphragm when the vacuum valve is closed, and means for controlling the operation of the valve apparatus, comprising a valve operating lever operatively connected to said plunger.

EDW RD ROGKWELL, 

